ISUZU 4JJ1 Euro 4 N Series Truck EGR Valve Removal and Installation Guide

When you need to replace new or used EGR valve,you need to remove and install EGR valve and cooler.Here comes the steps on how to remove and install EGR valve and cooler for ISUZU Euro 4 N series truck with 4JJ1 engine.

 

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Procedures:

1.Drain the engine coolant.

2.Remove the AC generator.

3.Remove the engine cover.

4.Remove the fan guide bracket right.

5.Remove the exhaust adaptor and turbocharger water return pipe.

6.Remove the degassing hose.

7.Remove the degassing pipe.

8.Remove the heat protector.

9.Remove the EGR cooler.

Remove the(IN) and(OUT) rubber hoses of the water pipe, and remove the EGR cooler and the gasket.

10.Remove the EGR valve connector.

11.Remove the EGR valve.

 

Installation

If the procedures or methods for assembling the EGR device are mistaken, that can lead to cracks of pipe or gas leaks. Always follow the procedures.

1.Install the EGR valve.

Tightening torque:27 N-m(2.8kg-m/20 lb-ft)

2.Install the EGR valve connector.

3.Install the EGR cooler.

a.Attach the gasket and the EGR cooler, and temporarily tighten them in the order specified in the diagram.

b.Securely tighten them at the specified torque in the order as shown in the diagram.

Tightening torque: Nuts, Bolts(1)-(5)27 N·m(2.8kg-m/20 lb-ft)

4.Install the (IN) and (OUT) rubber hoses of the water pipe.

Install the rubber hose(IN) so that it does not interfere with the exhaust manifold heat protector.

5.Install the heat protector.

Tightening torque:25 N-m(2.5kg-m/18 lb-ft)

6.Install the degassing pipe.

a.Attach the degassing pipe, and temporarily tighten them in the order specified in the diagram.

b.Securely tighten them at the specified torque in the order as shown in the diagram.

Tightening torque Nuts, Bolts

(1),(3),(4),(5):10N-m(1.0kg-m/87 lb-in)

Nut(2):25N-m(2.5kg-m/18 lb-ft)

7.Install the exhaust adaptor and turbocharger water return pipe.

8.Install the fan guide bracket right.

9.Install the engine cover.

10.Install the AC generator.

11.Refill the engine coolant.

For more guide about ISUZU,please refer to:ISUZU Trouble Repair.